2005 YAMAHA TMAX brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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9

10

*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
11

*
Wheels

Check runout and for damage.
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12

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Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
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13

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Wheel bearings

Check bearing for looseness or damage.
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14

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Steering bearings

Check bearing play and steering for roughness.
√√√√√

Lubricate with lithium-soap-based grease. Every 20000 km
15

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Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
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16

Sidestand, centerstand

Check operation.

Lubricate.
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17

*
Sidestand switch

Check operation.
√√√√√ √
18

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Front fork

Check operation and for oil leakage.
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19

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
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20

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Electronic fuel injection

Adjust engine idling speed and synchronization.
√√√√√ √
21

Engine oil

Change. (See pages 3-5 and 6-10.)
√
When the oil change indicator flashes
(every 5000 km)

Check oil level and vehicle for oil leakage. Every 5000 km
√
22

Engine oil filter cartridge

Replace.
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23

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
24

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
25

*
V-belt

Replace.When the V-belt replacement indicator flashes
(every 20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
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5
67
8
9

EAU18670
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
26

*
Front and rear brake
switches

Check operation.
√√√√√ √
27

Moving parts and cables

Lubricate.
√√√√ √
28

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√√√√ √
29

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
1
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9Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This model is equipped with tubeless
tires.
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12

Front tire:
Size:
120/70R14 M/C 55H
Manufacturer/model:
DUNLOP/D252F
BRIDGESTONE/TH01F
Rear tire:
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/D252
BRIDGESTONE/TH01R

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
2
3
4
5
67
8
9

EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU33451
Front and rear brake lever free
play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
EAU33473
Adjusting the rear brake lock
lever cable
Rear brake lock lever cable adjust-
ment may be required if the rear
brake lock lever does not hold proper-
ly. When the rear brake lock lever is
not in use, the rear brake lock lever
cable length should measure 45 mm
to 47 mm (1.77 in to 1.85 in) at the
rear brake caliper. Periodically check
the rear brake lock lever cable length
and, if necessary, adjust it as follows.
To increase the rear brake lock lever
cable length, turn the adjusting nut at
1. Adjusting nut
2. Rear brake lock lever cable length
2
1
(b)
(a)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
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the rear brake caliper in direction (a).
To decrease the rear brake lock lever
cable length, turn the adjusting nut in
direction (b).
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22493
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the rear brake caliper by in-
1. Brake pad wear indicator groove
1 1

1. Bolt
2. Lining thickness
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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67
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stalling the bolts, then tightening
them to the specified torque.
CAUTION:

ECA12822
Do not apply the rear brake or rear
brake lock after the brake caliper
has been removed, otherwise the
brake caliper piston will be forced
out.
EAU22580
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the brake fluid reservoir when
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
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refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
2
3
4
5
67
8
9

EAU23170
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU23210
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and met-
al-to-metal contact surfaces should be
lubricated if necessary.
WARNING

EWA10740
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)